Viscous Material Pump Speed Control for Motor Reserve Management
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Solution Overview
Problem
Existing construction-material and viscous-material pumps face issues with motor system overload and reduced conveying volume flow due to inadequate management of power and rotational speed, leading to inefficient operation.
Innovation Solution
A method and pump design that automatically adjusts the motor rotational speed based on required power and torque values to maintain a power or torque reserve above a predefined limit, ensuring efficient and uninterrupted conveying of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the motor system operates at high power to maintain conveying volume flow, then the conveying performance is improved, but the motor system becomes overloaded and rotational speed drops
Solution Approach 1:
The motor rotational speed is dynamically adjusted based on real-time power requirements and reserve values. The control method continuously monitors the operating point relative to the characteristic curve and modifies rotational speed to maintain optimal power reserve, preventing overload while ensuring sufficient conveying performance.
Solution Approach 2:
The method changes the motor operational parameters (rotational speed and power reserve) adaptively. By adjusting the rotational speed value based on the required power value and maintaining a power reserve value above the limit value, the system optimizes the balance between conveying performance and motor reliability.
2Reliability
If the motor rotational speed is increased to prevent overload, then motor reliability is improved, but energy consumption increases
Solution Approach 1:
The method optimizes energy consumption by dynamically adjusting the motor rotational speed to the minimum necessary value that still maintains the power reserve above the limit value. This avoids unnecessary high-speed operation while preventing overload, achieving energy efficiency without sacrificing reliability.
Solution Approach 2:
The control method employs feedback by continuously monitoring the power reserve value and adjusting the rotational speed accordingly. The system only increases rotational speed when necessary to maintain the power reserve above the limit value, and reduces it when the reserve is sufficient, thereby minimizing energy consumption while ensuring reliability.
3Productivity
If automatic control is implemented to manage power reserve, then operational efficiency is improved, but device complexity increases
Solution Approach 1:
The automatic control method uses feedback control to continuously monitor the power reserve value and adjust the motor rotational speed. This automated feedback mechanism improves operational efficiency by preventing overload conditions and optimizing performance without requiring complex manual intervention systems.
Solution Approach 2:
The control system performs self-adjustment by automatically modifying the motor rotational speed based on the monitored power reserve value. The system serves itself by detecting when the power reserve approaches the limit value and autonomously adjusting operational parameters, reducing the need for external control complexity.
Data Source
AI summary
A method for operating a construction-material and/or viscous-material pump for conveying construction material and/or viscous material has the steps of: a) determining a required value of a power or of a size of the motor system, corresponding to the power, for moving the conveying piston, b) setting, on the basis of the required value, a speed value of the motor system in such a manner that a power and/or speed reserve value between an operating point, wherein the operating point is defined by the required value of the power or of the size and the speed value, and a characteristic curve of the motor system, wherein the characteristic curve is defined by maximum values of the power or of the size and speed values, wherein maximum values are different for different speed values at least in sections, is greater than or equal to a reserve limit value.